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Design Process of CSTR For Production of Furfuraldehyde: Wordu A. A, Anthony O.J
Design Process of CSTR For Production of Furfuraldehyde: Wordu A. A, Anthony O.J
Abstract
A realistic academic cum industrial Isothermal continuous stirred tank reactor design, feed rate 11.51 kgs-1 furfuraldehyde
productions is presented. Principles of material balance and heat generated per unit volume equations were performed on the
reactor system to derive model equations applied in obtaining the reactor functional parameters. Mechanical concepts of the
reactor and the economics of the design were considered. The functional parameters of the reactor were computed using efficient
mat-lab program version 7.7 as shown. The hydrolysis and dehydration reaction of xylan and xylose respectively to furfural is
endothermic; a heating jacket is incorporated to account for the supply and maintenance of heat liberated.
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 193
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
Chemical Reaction of Furfural Production Rate of reactants loss due to chemical reaction = ri VR
, Hcl
Pentonsans + water pentose (1)
Substituting all the above into
Fi , o Fi , o 1 X i ri VR
Hcl
d
C5H8O4 + H2O 1
C5 H10O5 (CiV )
dt
FA,O 1 X A rA V R (C AV )
, Hcl
d
Pentose furfural + water (2) F A,O (6)
dt
, Hcl
C5 H 10 O5 C5 H 4O2 + 3H 2 O Assumptions for the reactor;
The feed is well stirred or properly mixed.
Kinetic Scheme for Furfural Production [4], [7]
Neglecting the inflow rate of catalyst and solvent.
Pentosan pentose
1 k 2 k
furfural
Steady state operation.
Let, Pentosan = A, Pentose=B, Furfural=C
Isothermal and non-adiabatic system.
rXylan dC A
Rate of Pentosan hydrolysis: = = k1C A Constant density system.
dt
Cylindrical tank with hemispherical head.
dC B
Rate of Pentose reaction [9]: rXylose = = Applying the assumptions where necessary into equation (1)
dt gives;
k1C A k 2 C B (3)
FA,O FA,O 1 X A rA VR
dCC
Rate of furfural formation: rfurfural = = k2CB (4)
dt F A,O X A
FA,O FA,O FA,O X A rA VR V R
rA
(7)
E A ,i
k i A0,i H 2 SO4 % i
m
Rate of reactant flow into element of volume = Rate of Substituting (9) into (8):
reactant flow out of element of volume + Rate of reactant
loss due to chemical reaction within element of volume + rA k2CA 1 X A (10)
Rate of accumulation of reactant in element of volume [9].
Substituting (3) into (4) :
Rate of reactant flow into element volume = Fi ,o
FA,O X A
VR (11)
k2C A 1 X A
Rate of reactant flow out of element of volume (with respect
to fractional conversion) = Fi ,o 1 X i
r 2 H
FA,O X A
HR
FA,O X A
(13) qR H r X Ak1CA 1 X A (23)
k2C A 1 X A , r k2C A 1 X A
2
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 195
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
h j de Np P
Where: 0.023Re 0.8 Pr 0.33 (40)
k Fr m
n D 5 st
3
a log Re
h j hd m (41)
Uo b
h j hd
(30)
Further simplification can be made at low and high
Where: Reynolds number;
1 1 N p kT
Stirrer Diameter Dst : Dst
(45)
to DR (34)
2 4
Substituting (38) into (37):
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 196
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
kmol
CA 10.79(1 0.95) , C A 0.5395
Taking the temperature of the reaction 175 C :
m3
T 175 C 448K
Pressure of Reactor
Hydronuim ion concentration as 0.3% : H 0.03
kmol dm 3
PR 0.01079 0.082atm 448K
dm 3 kmolK J
R 8.314
molK ,
PR 0.4atm 1atm 1.4atm
k1 4.88 105 s 1
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 197
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
137 , 300 J
mol
Where: Q H R F A,O X A
k1 0.03
8.314 j 448 K
1.85
3.27 1014 s 1 molK J 3 kmol
, Q 277,604,400 1.09 10 0.95
211, 300 J kmol s
mol
k 2 0.03
j
8.314 molK448 K
1.608 10 22 s 1
0.06
J KJ
, Q 287,459.36 C pw 1.851
At 200 C
s, kgK
k 2 3.00 10 3 s 1
The heating fluid enters the jacket at 200 C and leaves at
Reactor Head Dimension 45 C
Where:
T T1 T2 ,
DR 6m ,
T 200 C 50 C ,
DR
HH ,
2 T 150 C 423K ,
6m 287.46 KJ s
HH , m w
2 1.851KJ kgK 423K
Jacket Dimension
rR 3 ,
2
VH
3 Height of jacket:
qR = 426,837.6 J. m3 s−1 Hj
Ns
Mat lab 7.7 is used to solve the design equations to give the
Pj
,
functional parameters of the reactor such as Volume of
0.9m
reactor, space velocity, space time and length of reactor. Ns
0.2m ,
3.10 Heating Jacket Design [5],[9]
Mass Flow Rate of Heating Fluid N s 4.5 5
Q Length of Jacket:
m w
C pw T
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 198
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
h j 0.24
Hydraulic diameter d e : 0.023856505.5 0.390.33
0.8
3
663.31 10
40.3 0.2 hj = 2597W.m-2K-1
de ,
20.3 0.2
Overall Heat Transfer Coefficient
d e 0.24m h j hd
Uo
h j hd
Velocity through channel u : u m
A j
Where;
kg 1
0.37 hd
Where;, ρ = 1000kg. m3 , u s fd
kg
1000 3
0.06m 2
m Where,
m
u 6.17 10 3
s m2 C
f d 0.0025
W
Film Heat Transfer Coefficient for the Jacket
1
Reynolds number
(Re) : hd
0.0025
ud e
Re hd 400
W
m2 C
134.5 106 Pa.s 1 1 1
U o 2597 400
1000 0.48 0.24
Re
134.5 106 W
U o 346.62
Re 856505.5 m C 1
2
C 1.0m n 90r
Taking min
Stirrer length
Lst The stirrer type is a radial turbine with 6 blades
Re 60
1.7912 10 2
Lst 1.8m 1.0m
Re 2,683,117.46
Lst 0.8m
Since Re10 4 , the flow regime is turbulent and the power
Diameter of stirrer
Dst consumption is independent of the Reynolds number.
DR N P KT
Dst
4
Where KT 6.30 (Peters M.S, 2004)
6m
D st
4 P K T D 5 st n 3
D st 1.5m
P 6.30
1424
1000
5
1.5 90
60
3
Stirrer blade width
W
P 0.229KW 0.23KW
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 200
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
Volume of Reactor(m.3)
40
2
p R 1.4atm 1.013 10 Nm 5
141,855 pa
30
DR 6m 20
10
S 66,900103 pa
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
c 0.0032 The plots shows that volume of the reactor increases slowly
at different fractional to a point where there is a rise in the
141,855 6m volume increase till it gets to infinity.
t 0.0032
66,900 103 0.6 0.6 141,855 x 10
5
Heat Generated VS Fractional Conversion
3.5
t 0.024m 3
2.5
Heat Generated(KJ/sec)
Temperature
1
Allowable pressure
Mechanical properties such brittleness, low thermal 0.5
conductivity.
PH 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Heat transfer rate Fractional Conversion
2
Mat lab (7.7) was used to simulate the reactors parameters
and the results presented on graphs. 1.5
1
The discussion is on the graphs plotted with result of
0.5
simulation using Mat lab. The graphs are;
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Fractional Conversion
The graph gives a negative straight line graph which shows The graph for the reactor shows a steady rate till a point the
that the heat generated is directly proportional to fractional rate starts to reduce till it gets to infinity. The graph can be
conversion use as a model to determine the volume of the reactor at any
fractional conversion. This is done by multiplying the flow
0.35
Space Velocity VS Fractional Conversion rate by the area under the curve from the point of the
required fractional conversion.
0.3
-3
x 10 Rate of Reaction VS Fractional Conversion
1.8
0.25
Space Velocity(sec.-1)
1.6
0.2
1.4
0.15 1.2
Rate of Reaction
0.1 1
0.8
0.05
0.6
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0.4
Fractional Conversion
Fig 4 Plot of space velocity against fractional conversion 0.2
4
0
x 10 Space Time VS Fractional Conversion 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
3.5 Fractional Conversion
Fig 7 Plot of Rate of reaction against fractional conversion
3
2 fractional conversion.
1.5
5. CONCLUSION
1 The design process accommodates the general principles of
material and heat balances, rate law, kinetics, economics and
0.5 mechanical aspects to bring to bear the designing of the
CSTR of capacity. This is a typical pragmatic design that
0 can be operationalised by private sector.
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Fractional Conversion
Fig 5 plot of space time against fractional conversion NOMENCLATURE
The graph shows that the time taken to react one reactor
∆ = Heat
volume of feed increases with the fractional conversion
K1,k2 = Rate constant
slowly to a point, it increases till it goes to infinity.
rxylan = Rate of xylan hydrolysis
x 10
4
Rate of Reaction inverse VS Fractional Conversion rxylosee = Rate of xylose dehydration
7 rfurfural = Rate of furfural hydrolysis
CA= Final concentration of A
6 CB= Final concentration of B
CC= Final concentration of C
5 CAC= Initial concentration of A
Rate of Reaction inverse
FAO= Initial molar flow rate of specie [7]. Marcotullio G, (2005) “The chemistry and technology
π = Pie of furfural production in modern lignocelluloses-feedstock
r = Radius bio-refineries”, Arkh Edisioni, Rome. pp 10, 15, 20
LH = Length of reactor [8]. Nevers N, (2005) “Fluid mechanics for chemical
VH = Volume of reactor head engineers” 3rd Edition, McGraw-Hill, Singapore. Page 565
L = Length [9]. Octave L, (2001) “Chemical reactions engineering” 3rd
RTD = Resident Time Distribution edition, Wiley, New Delhi. Pp 84, 85, 86 Page 127.
τ = Space [10]. Peter M.S, Timmerhans D.K, West E.R, (2004)”Plant
SV = Space velocity of reactor Design and economic for chemical engineers”5th edition,
qR = Heat generated per unit volume of reactor McGraw-Hill, Singapore. PP 536, 539, 597.
LST = Length of stirrer [11]. Smith R, (2008) “Chemical process design and
C = Clearance of stirrer integration”, 3rd edition, Wiley, Singapore. Pp 78, 97
DSt = Diameter of stirrer [12]. H. E. Hoydonckx, W. M. Van Rhijn, W. Van Rhijn, D.
B = Wall baffle E. De Vos, P. A. Jacobs "Furfural and Derivatives" in
P = Power Ullmann's Encyclopedia of Industrial Chemistry 2007,
NP = Power number Wiley-VCH, Weinheim.
n = Number of revolution doi:10.1002/14356007.a12_119.p029
ρ = Density [13]. Perry and Green, (1998); Perry’s Chemical Engineers
f = Function Handbook, 7th ed., McGraw Hill, New York, PP. 23-4, 5.
R e = Reynold number
fr = Froude number BIOGRAPHY
Sn = Reactor dimension number Animia A. Wordu (PhD) was a Senior
μ = Viscosity Process Technologist with many years of
m = Mass flow rate industrial experience with the Port Harcourt
∆HR = Heat of reaction Refining Company, Alesa – Eleme, Port
∆T = Change in Temperature Harcourt, Nigeria; before going for his
Hj = Height of the jacket Doctorate degree with the Rivers State
Lj = Length of the jacket University of Science and Technology, Nkpolu, Port
Pj = Pitch of the spiracles Harcourt, Nigeria. After completion of PhD, was retained as
Aj = Area of heating jacket a Lecturer 1 with the Department of Chemical/
de = Hydraulic diameter Petrochemical Engineering. His researches are majorly
u = Velocity tailored to the Process Industry especially Reactors and
Chemical Engineering Thermodynamics.
Pr = Prandlt number
k = Thermal conductivity
hj = Film heat transfer of the heating jacket
hd = Film heat transfer coefficient of dirt
fd = Dirt factor
Uo = Overall transfer coefficient
∆Tlm = Log mean temperature
REFERENCES
[1]. Bhattachanyya B.C, (2005) “Introduction to chemical
equipment design (Mechanical aspect)” 1st Edition, CBS,
New Delhi. PP 29, 39, 246.
[2]. Dimian C.A, (2005) “Integrated Design and Simulation
of chemical processes”, volume 13, 1st Edition, Elsevier Inc.
USA page. 127.
[3]. Dussan K., Girisuta B., Haverty D., Leachy J.J., Hayes
M.H.B “kinetics of levulinic acid and furfural production
from miscanthus x giganteus”.Bioresources technology.
Page 24
[4]. Joseph B. B (2010) “Synthesis of furfural from xylose
and xylan”. Chemsuschem energy and materials 1268-1278.
[5]. Kern, D.Q, (2006) “Process heat transfer”, 1st edition,
McGraw-hill, USA Page 127.
[6]. Manuel A.V., Robeiro da silva, Maria D.M.C., (2012).
Thermochemistry of D-xylose. Journal of chemical
thermodynamics. 58(2013). Pp 20-28
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Volume: 05 Issue: 07 | Jul-2016, Available @ http://ijret.esatjournals.org 203